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Rough design info and some of my thought processes whilst designing this gizmo. I have probably altered some of the ideas to improve functionality and ease of use. Video at http://vimeo.com/18780151 with additional pictures at http://s917.photobucket.com/albums/ad19/picclock/Cheapo...

Rough design info and some of my thought processes whilst designing this gizmo. I have probably altered some of the ideas to improve functionality and ease of use. Video at http://vimeo.com/18780151 with additional pictures at http://s917.photobucket.com/albums/ad19/picclock/Cheapo...

Thanks for the replies. I thought I'd get away with the hardening issue as my silver solder melts at 640C, so I may have to rethink the method of fixing. I could try an interference fit or a heat shrink/ interference fit - at least it would be square. The part is not subject to heat during use...

I'm about to start manufacture of a part which requires a 10mm dia steel tube brazed into a 10mm thick steel plate. The rod is hardened steel and needs to be at right angles to the surface of the other part. Problem is that I need to allow about 4 thou clearance to allow the braze to flow (2...

@Mosey It does work. It also probably produces toxic gas, but I doubt very much you would be near enough to be affected. An ordinary pencil works just as well if your worried, although it will wipe off with your fingers. Just apply it before the pallions/flux. Best Regards picclock

@blackfoxsteam 2nd Bogstandard's post. Silver soldering is an excellent way to join metals if you follow a few rules. Use furnace bricks to reflect the heat to ensure no cold spots. To prevent the braze running use tippex or just pencil, which seems to work well. To remove the flux dunk in...

@ mcostelo Had you hardened the drill rod or was it used as is ?. Unhardened its only around mid 20's rockwell C, but hardened its supposed to be over 60 - which as far as I know - is pretty hard. If it was hardened and broke it may be that it needed more tempering or material with more give...

@mcostelo Why did it fail - what was the problem? Was the rod hardened ? Commiserations Best regards picclock

@ Marcello Thanks for the links - looks like I might need two reamers (if I can get an R7 one) or I may have to do some accurate boring on the lathe. I looked at quite a few pages but none of them clearly identified the issue as those links did. Many thanks picclock

This is the first time I've ever contemplated using a drawn cup needle roller bearing and I'm a little unsure of the process and problems/issues. I'm intending to use it in Aluminium and I'm puzzled about the housing tolerances. My intended size is 10mmx14mmx10mm. The table on the right...

For irregular shapes it can be very tricky to get the centre. A very crude method which seems to work well for me is to use a flat bar with a bolt/hook at one end, which has one face touching the work and another hooked on something around the same height so that the bar is roughly level with...

@ bogstandard Many thanks for the info. That's a neat way of doing it, although the problem I forsee is with filing the last inside part of the teeth, however seeing the diagram of the tooth cutting makes me think it should be easily do able. The nice thing about making one's own is that the...

I need a pair of bevel gears for 1:1 right angle drive to operate an inlet valve. Sadly I have no idea how to manufacture same. I have a lathe and mill but the way I see it I think you would need a shaper to make these. I looked up prices to buy ready made and needed to sit down after the shock...

@ Herbiev Built it to remove M3 broken tap which I will do today. Operating current best set by adjusting the insertion distance of the core in the solenoid. The further in the less current. Best operation on 12V high setting. After 5 mins on BDMS. White dot at bottom of hole is where I...

Video Links http://player.vimeo.com/video/44200887 With paraffin bath :- http://player.vimeo.com/video/44200886 Best Regards picclock

Does it work - very well I think. test with paraffin seemed to work best so far. Only problem is solenoid coil gets quite hot if pushed. Erosion rate in BDMS seems quite good, around 0.3mm per 5 mins. Will post video of operation when they have finished uploading. Almost seems to good to...

Made up an electrode holder, 1/2" brass, M6 tapped, piece of M6 studding (threaded rod) and M6 tapped nylon insulator. Electrode is currently some brazing wire, held in place by 2 M3 grub screws. Connection to electrode by crimped spade terminal. Moving post support drilled and reamed 6mm for...

I built it and it seems to work. I found an old junked solenoid in the shed and stripped it down removing former, and milled off the encapsulated mains voltage coil. Rewound with wire I had lying around, just had enough to fill the bobbin.

I've been clumsy enough to break another M3 tap and need to remove its remains. Most of the spark eroders I've seen use a wire which is fed into the work and a current limit, usually light bulbs. This leads to continual wire adjustment. However on you tube I saw a spark eroder using a door bell...

The pump is a scavenger pump to recycle fluid/vapour mixture. Amazingly, to my small mind, I checked on ebay and there are loads of rings and even piston sets for this size, 40mm. There is a chainsaw set with piston, wrist pin and ring for £12 delivered...